SNG aus Biomasse am Beispiel Göteburg

SNG aus Biomasse am Beispiel Göteburg

Bioenergy 2020+ - Biomassetag November 2017

Overview

Graz

(Head office)

Güssing Wieselburg

Pinkafeld Tulln

WHAT

WHERE

WHO

career levels (mostly engineers)

HOW

(~9 Mio EUR turnover per year)

Research Areas

Biomass combustion

Gasification Systems Biological Conversion & Integration

Three main research areas:

1. Combustion 2. Gasification 3. Bioconversion

Plus a number of additional departments: microgrids, simulation, automation and supply chain.

BIOENERGY 2020+ GmbH, a limited company is owned mostly by public ins- titutions like universities, ministries and similar public bodies. The single biggest owner is an association of enterprises with commercial interest in the field.

Bioenergy 2020+ enterprise and ownership

~20 individual firms

Gasification & Synthesis Value Stream

Gasification + Synthesis

Waste, feedstock byproducts

• Wax

• Kerosene

• Alcohols

• Diesel

• Electrical

• Thermal

• Hydrogen

• Gas - SNG

Optional: Peak-wind energy

Shifting Research Focus

Energy Gases Substances

Shifting the reseach focus towards higher-value products

Product range

Including recycling of phosphorus from sewage sludge and

agricultural sources. Biofuels

Energy & Heat Chemicals

Feed

& Food Health

& Cos- metics

increasing market value

Dual Fluidized Bed (DFB)

Steam Gasification Technology

Production of Synthesis Gas: Starting point for SNG

to stack gas motor, H₂,

CH₄, fuel, wax, … Biomass is converted into

mostly hydrogen and carbon monoxide – a so-called

synthesis gas.

Synthesis gas is the starting point for a number of

downstream conversion processes, like SNG production.

DFB Reactor and System Integration

Güssing Plant Layout

Syngas via Steam Gasification: State of the Art

Gasification

Electricity (Gas engine)

Heat (District heating)

Synthesis gas H2 + CO

Cooling (optional)

Green chemistry

Carbon source Biomass (wood, …) Agricultural-residues Municipial waste (plastic, sewage sludge…)

The DFB gasification system achieved several 100,000 hours of operating experience with sev- eral plants in the range of 0.5 to 32 MW thermal power. The demonstration plant in Güssing achieved more than 100,000 hours of operation.

As alternative to CHP, the synthesis gas can be used to produce fuels and chemicals via catalytic synthesis.

State of the art is synthesis gas utilization in a gas engine for the generation of elec- tricity, as well as waste heat utilization for

Syngas: Synthetic Production Routes

Liquids & Waxes Gases

Synthetic Natural Gas (SNG)

Hydrogen

Ammonia

FT Fuels & Chem- icals (diesel, wax,

kerosene, …) Mixed alcohols

Synthesis gas H2 + CO

Methanol Isosynthesis -

Isobutane

Oxosynthesis - Aldehyde Carbon source

(biomass, residues, waste)

Gasification

A number of different routes for synthesis of gaseous and liquid chemicals is possible

Methanation: SNG from Syngas

CH

O

 H

+ CO + CH

+ CO

3H

+ CO  CH

+ H

O

nickel catalyst with some pre- and after-treatment of the gas.

SNG to grid

Syngas from gasifier Must be separated

Methanation: SNG from Syngas - Details

Syngas from gasifier

Tar removal

Compre ssion

Pre- heating H₂S

removal

2^nd H₂S removal

Heat recovery NH₃

removal Compre

ssion CO₂

removal H₂O

removal

H₂

removal

Bio-SNG to grid

Status of SNG Production

Overview of Gasification Plants

Location Usage / Product Fuel / Product

MW, MW Start up Supplier /

Engineering Status

Güssing, AT Gas engine 8.0_fuel / 2.0_el 2002 AE&E, Repotec End of demonstration life time reached

Oberwart, AT Gas engine /

ORC / H₂ 8.5_fuel / 2.8_el 2008 Ortner

Anlagenbau On hold / restart?

Villach, AT Gas engine 15_fuel / 3.7_el 2010 Ortner

Anlagenbau On hold / restart?

Senden/Ulm,DE Gas engine /

ORC 14_fuel / 5_el 2011 Repotec Operational

Burgeis, IT Gas engine 2_fuel / 0.5_el 2012 Repotec,

RevoGas On hold

Göteborg, Sweden BioSNG 32_fuel/20 _BioSNG 2013 Repotec/ Valmet Operational / On hold

California R&D 1 MW _fuel 2013 GREG Operational

Gaya, France BioSNG R&D 0,5 MW _fuel 2016 Repotec Operational

Thailand Gas engine 4MW_fuel / 1MW_el 2016 GREG Operational

Overview

Key figures:

• 32 MW fuel power

• 20 MW SNG output

Performance target:

• Efficiency: >65%

• Time efficiency: 8000 h/a

Status:

Operational but intended scale- up (4x) on hold due to perfor- mance issues.

Plant Complexity: SNG vs. Heat and Power

SNG plant

(GoBiGas) Heat & Power (Güssing)

SNG Efficiency (Vesta process)

Biomass to SNG efficiency: 65%

ISBL

CAPEX vs. Feed Capacity for Various DFB Projects

0 5 10 15 20 25 30 35 40 45 50

0 5 10 15 20 25 30 35 40

Senden

Total CAPEX [Mio EUR]

Güssing Oberwart Nongbua

GoBiGas

Estimated CAPEX for various DFB projects (only gasification parts considered here) show that GoBiGas CAPEX is above expectations.

CAPEX here is estimated for ISBL, which does not include auxiliary installations.

CAPEX Learning Curve

Corrected for the annual plant cost index (steel price, inflation, …) and in the order of the

cumulated fuel power, a certain learning effect is evident.

- 500.000 1.000.000 1.500.000 2.000.000 2.500.000

0 20 40 60 80 100 120

Specific CAPEX* (2016) in EUR MW-1

Cumulated fuel power in MW Güssing

Oberwart

Villach

Senden

GobiGas

Economic viability: Production costs for SNG

Raw materials Operating labor Utilities

Employee benefits Supervision

Laboratory Maintenance Insurance and taxes Operating supplies Plant overhead Depreciation

Approx 50%

of the prod- uction costs are CAPEX- related costs (fixed costs).

Production costs

raw materials

labour

utilities maintenance

insurance &

tax

depreciation

Approx 50% of the production costs are

operating costs (variable costs).

operating supplies

Time Efficiency: yearly operating hours

0 5.000

2016 2014 2015 2017

Ø 2.506

7.708

0 5.000

2008 2010

2007

2002 2003 2004 2005 2006 2009 2011 2012 2013 2014 2015

Ø 6.356

operating hours / year [h/a]

GoBiGas (SNG)

Güssing (Heat&Power)

0 5.000

2012 2013 2014 2015

Ø 3.746

2016

Senden (Heat&Power)

Target

On average: ~30%

of target operating hours achieved

Economic viability: A sensitivity analysis

Values Units

Investment costs

(incl. startup expenses)

29 700 000 EUR

Expenses 9 921 840 EUR a^-1

SNG selling price for NPV = 0 130 EUR MWh^-1

20 MW_th plant

Natural Gas in Austria: ~50 EUR MWh^-1

Economic viability: A sensitivity analysis

Slide 24

-30%

-20%

-10%

0%

10%

20%

30%

40%

-30% -20% -10% 0% 10% 20% 30%

SNG price variation

Variable variation Capital

Wood price Operating hours

How fuel cost,

CAPEX and operat- ing hours influence the cost of SNG.

Highest sensitivity:

Operating hours!

Conclusions: Main Challenges for SNG

1 2 3

Complexity and Reliability

R&D must not only focus on energetic efficieny, but strife for simplicity and reliability of plant layout and operation.

CAPEX &

Investment

Investors need to plan for realistic time frames and

targets. Big players + funding with good stamina needed!

Learning &

Experience

(Almost) none of the shown plants have been build by the same consortium, there are improvements, but there could be more.

Contact

Bioenergy2020+ GmbH

Biomass Gasification Systems Wienerstraße 49

7540 Güssing Austria

Research Area Manager Gasification Systems

markus.luisser@bioenergy2020.eu T + 43 (0) 3322 42606-151

Unit Head | Syngas Processes gerald.weber@bioenergy2020.eu T + 43 (0) 3322 42606-154

Unit Head | Gasification

matthias.kuba@bioenergy2020.eu T + 43 (0) 3322 42606-156